3D Printer Floating Solution Reduces Resin Consumption
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Solution Overview
Problem
Existing 3D printers require large amounts of photocurable resin, leading to high initial and operational costs, as only the surface portion of the resin is used for printing, and changing resin types necessitates replacing the entire resin in the water tank.
Innovation Solution
A 3D printer design that fills most of the water tank with a denser floating solution, which supports the resin and allows for separate handling, reducing resin usage and costs by maintaining the floating solution intact during resin changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the water tank is fully filled with photocurable resin, then the printing operation can be performed, but the initial operation cost and use cost become very high due to large resin consumption
Solution Approach 1:
The patent divides the water tank into two distinct liquid layers: a floating solution occupying the majority of the tank volume and a thin layer of photocurable resin on the surface. This segmentation allows the resin to be used only when needed for printing, while the floating solution serves as a cost-effective base medium that does not require replacement or consumption during normal operation.
Solution Approach 2:
The floating solution acts as an intermediary substance between the air and the photocurable resin. It provides a supportive medium that enables the resin to float on its surface, allowing the build platform to pass through the floating solution to access the resin layer without requiring the entire tank to be filled with expensive resin.
2Adaptability or versatility
If all resin in the water tank is replaced to use different resin types, then resin type switching is achieved, but the cost and complexity increase significantly
Solution Approach 1:
By segmenting the tank contents into a permanent floating solution layer and a replaceable resin layer, the patent enables independent handling of each component. The floating solution remains in the tank and serves as a reusable base, while only the thin resin layer needs to be removed and replaced when changing resin types, dramatically reducing the material cost and complexity of resin switching operations.
3Productivity
If the build platform passes through the resin layer, then printing operation is enabled, but resin mixing with floating solution occurs, compromising material purity
Solution Approach 1:
The patent utilizes hydraulic principles by employing two liquids with different densities (floating solution and resin) that naturally separate into distinct layers due to gravity. The build platform passes through the less dense floating solution to reach the resin layer on the surface. This density-based stratification maintains material purity while enabling the build platform to access the resin for printing operations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Significantly reduces initial operation and use costs by minimizing resin consumption and enabling easy switching between resin types without replacing the floating solution, while ensuring stable resin support during printing.
Implementation Method 1
the floating solution is not mixed with the resin, has a higher density than the resin, and supports the resin
Implementation Method 2
the floating solution is not mixed with the resin, has a higher density than the resin
Implementation Method 3
the resin and the floating solution may be separated from each other by gravity
Data Source
AI summary
A three-dimensional (3D) printer including a floating solution for reducing resin usage may include a main frame, a water tank disposed inside the main frame, a build platform slidable in a vertical direction along the water tank, an optical assembly disposed at an upper portion of the main frame and irradiating a laser beam to the build platform, resin contained inside the water tank, and the floating solution contained inside the water tank, wherein the floating solution is not mixed with the resin, has a higher density than the resin, and supports the resin.